Creating Comfort: Diy Foam Arom Shoulder Pads

Foam armour shoulder pads can be made using craft foam or EVA foam, and can be used for cosplay. The process involves creating a pattern, cutting and tracing the pattern onto foam, sanding, gluing, and painting. The number of layers of foam and glue used will depend on the desired durability of the armour.

Use craft foam or EVA foam

Craft foam and EVA foam are great options for making foam armour shoulder pads. They are inexpensive, easy to work with, and can be shaped and painted to create a variety of different looks. Here is a step-by-step guide to making foam armour shoulder pads using craft foam or EVA foam:

Materials and Tools

You will need three sheets of craft foam or EVA foam (12"x18" each sheet), a sharp knife or scalpel, a glue gun, paint, a gluing surface like a silicone baking mat, sandpaper, and a pattern or template. You can create your own pattern by drawing half of the shoulder pad on paper and then cutting it out, or you can find templates online.

Cut and Trace the Pattern

Print and cut out your chosen pattern, ensuring it is to scale. Place the pattern pieces on the foam and trace around them with a ballpoint pen. Cut the foam carefully with your sharp knife, being mindful of your fingers.

Sand the Foam

Use sandpaper to roughen the edges of the foam, especially where you will be gluing pieces together. This will help create a stronger bond.

Assemble the Pieces

Follow your pattern's instructions for assembling the pieces. Use hot glue to attach the foam pieces together, working in small sections and holding them in place until the glue cools. You can also use contact cement, especially if you want your shoulder pads to curve, but be aware that it is flammable and toxic.

Add Details

Use a gift card or similar tool to create recessed lines in the foam for added detail. You can also add rivets, either by pressing the back of your pen into the foam to create indentations or by using epoxy to create 3D rivets. Paint your shoulder pads to achieve the desired look.

Attach the Shoulder Pads to Your Costume

Finally, attach the shoulder pads to your costume by sewing them in place or using another method of attachment, such as velcro or webbing.

Cut out the pattern

Now that you have your tools and materials ready, it's time to start crafting your foam armour shoulder pads! The first step is to create the pattern, which will serve as the template for your shoulder pads. Grab some white paper and a coloured pen, and draw out the first half of your desired shoulder pad shape. This is an important step as it will ensure that your shoulder pads are symmetrical and evenly shaped. Take your time with this step, as a well-drawn pattern will make the rest of the process easier.

Once you're happy with your pattern, carefully cut it out using a sharp cutter, knife, or scalpel. Remember to cut as close to the line as possible without removing the line itself, as this will ensure accuracy when transferring the pattern to the foam. After cutting, you should have a paper template of the first half of your shoulder pad.

Now, it's time to transfer the pattern to your craft foam or EVA foam. Place the paper pattern onto the foam and use a ballpoint pen to trace around it firmly, holding the pattern still so it doesn't move. This will leave you with an indented line on the foam, creating a clear outline to follow when cutting. Repeat this process, making sure to flip the pattern over to create a mirror image for the second half of the shoulder pad. You should now have two foam shapes that, when put together, will form a complete shoulder pad.

Tips for Cutting the Pattern

• Use a very sharp knife or scalpel when cutting the foam to achieve clean, precise cuts. A dull knife will result in rough edges.
• Always be cautious and mindful of your fingers when cutting, to avoid accidental cuts.
• When cutting holes or intricate details, use a hole punch or a smaller, more precise tool to achieve clean results.

Sand the borders

When making foam armour shoulder pads, sanding the borders is an important step to ensure a smooth and professional finish. Here are some detailed instructions on how to sand the borders effectively:

Tools and Materials:

Before you begin, gather the necessary tools and materials. You will need:

• Coarse sandpaper or a higher-grit sandpaper (150-220 grit) for a smoother surface.
• A sanding block or a Dremel tool for more precise sanding.
• A blowtorch (optional) for an extremely smooth finish.

Preparing the Foam:

Before sanding, make sure your foam pieces are cut to the desired shape and size. Use a sharp knife or a hot knife to cut the foam, as dull blades can create jagged edges. If using a hot knife, be cautious of the fumes and work in a well-ventilated area.

Sanding Technique:

• Start by using coarse sandpaper or a sanding block to roughen the edges of the foam that require smoothing. Sand with the grain of the foam, applying even pressure to avoid creating divots.
• For more detailed work or complex shapes, a Dremel tool with a sanding attachment can be used. This will allow you to sand harder-to-reach areas and create a more precise finish.
• If desired, apply gentle heat to the sanded edges with a blow dryer or heat gun. This will help smooth out any remaining imperfections and create a more polished appearance.
• For an even smoother finish, use a finer-grit sandpaper and repeat the sanding process. This will help refine the edges and remove any remaining rough spots.
• Finally, if you want an extremely smooth and professional finish, carefully pass a blowtorch flame over the sanded edges. The heat will smooth out any remaining imperfections, leaving a sleek and polished surface.

Remember to work carefully and wear appropriate protective gear, including gloves and a respirator, when sanding and working with heat.

Use contact cement to stick the pieces together

Contact cement is an adhesive used to bond plastics. It is very resistant and doesn't leave lumps when dried. However, it is important to note that the fumes are toxic and the product is flammable, so it should be used outside or in a well-ventilated area. Consider using a respiratory mask when applying contact cement, and keep it properly sealed and stored outside your working area when not in use.

To use contact cement to stick the pieces of your foam armour shoulder pads together, start by pouring a small amount of the cement along the border of one of the pieces. Do the same with the other piece while the first one dries a little, and then press them together until they bond. This will help the shoulder pad to curve.

It is also possible to use hot glue for this step. If you choose to use hot glue, a glue gun with a temperature control is highly recommended to prevent burns.

Seal and prime the armour

Sealing and priming your foam armour is a crucial step in achieving a smooth, professional finish. Here is a detailed guide on how to seal and prime your foam armour shoulder pads:

Seal the Armour

Sealing the foam armour is necessary to prevent paint from seeping into the pores of the foam, resulting in an uneven and less aesthetic finish. There are various methods and products available for sealing foam:

• Heat Gun Method: Use a heat gun to pass over the foam until you see a slight glimmer or sparkle on the surface. Do this twice to ensure the entire area is covered. Once the foam has cooled, apply a sealant.
• Sealant Products: You can use sealants such as Rosco's Flexbond, PVA glue, Mod Podge, or specialised products like SEAL Prime, which is a flexible foam sealer and primer. SEAL Prime can be applied as a spray or brushed on and comes in different colours (Matt Grey, Matt Black, and Matt White).

Prime the Armour

Priming the armour prepares the surface for painting and helps create a smoother finish. Here are the steps to prime your foam armour:

• Apply a Primer: Once the sealant is dry, apply a primer to the foam armour. You can use an automotive filler primer spray paint or a product like Gesso, a primer commonly used for art projects.
• Sand the Surface (Optional): Before priming, you may want to use coarse sandpaper to roughen the foam surface, especially in areas where you plan to glue other pieces. Sanding creates a better surface for gluing and helps the primer adhere better.
• Allow for Drying: Ensure that you follow the manufacturer's instructions for drying times between coats. For example, with Rosco's Flexbond, it is recommended to let the sealant dry overnight before proceeding to the next step.

By following these steps and allowing adequate drying time, you will seal and prime your foam armour shoulder pads, creating a smooth base for painting and customisation.

Frequently asked questions